U.S. patent number 11,296,449 [Application Number 16/863,170] was granted by the patent office on 2022-04-05 for electrical connector assembly having identical electrical connectors.
This patent grant is currently assigned to Lear Corporation. The grantee listed for this patent is Lear Corporation. Invention is credited to Anthony Butcher, David Menzies, Bhupinder Rangi.
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United States Patent |
11,296,449 |
Menzies , et al. |
April 5, 2022 |
Electrical connector assembly having identical electrical
connectors
Abstract
An electrical connector assembly includes first and second
electrical connectors that are identical in structure. The first
electrical connector includes a first housing component having a
terminal recess provided therein, a second housing component having
a terminal recess provided therein, and a wire terminal assembly
including an electrical terminal that is supported by the terminal
recesses provided in the first and second housing components of the
first electrical connector. The second electrical connector also
includes a first housing component having a terminal recess
provided therein, a second housing component having a terminal
recess provided therein, and a wire terminal assembly including an
electrical terminal that is supported by the terminal recesses
provided in the first and second housing components of the second
electrical connector. The electrical terminal of the first
electrical connector and the electrical terminal of the second
electrical connector engage one another.
Inventors: |
Menzies; David (Linden, MI),
Butcher; Anthony (Troy, MI), Rangi; Bhupinder (Novi,
MI) |
Applicant: |
Name |
City |
State |
Country |
Type |
Lear Corporation |
Southfield |
MI |
US |
|
|
Assignee: |
Lear Corporation (Southfield,
MI)
|
Family
ID: |
1000006216335 |
Appl.
No.: |
16/863,170 |
Filed: |
April 30, 2020 |
Prior Publication Data
|
|
|
|
Document
Identifier |
Publication Date |
|
US 20210344133 A1 |
Nov 4, 2021 |
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01R
13/28 (20130101); H01R 24/84 (20130101); H01R
13/6456 (20130101); H01R 13/6271 (20130101) |
Current International
Class: |
H01R
13/28 (20060101); H01R 13/645 (20060101); H01R
24/84 (20110101); H01R 13/627 (20060101) |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Gushi; Ross N
Attorney, Agent or Firm: MacMillan, Sobanski & Todd,
LLC
Claims
What is claimed is:
1. An electrical connector assembly comprising: a first electrical
connector including a first housing component having a terminal
recess provided therein, a second housing component having a
terminal recess provided therein, and a wire terminal assembly
including an electrical terminal that is supported by the terminal
recesses provided in the first and second housing components of the
first electrical connector, wherein portions of the first housing
component and the second housing component engage one another to
retain the first housing component and the second housing component
of the first electrical connector together; and a second electrical
connector including a first housing component having a terminal
recess provided therein, a second housing component having a
terminal recess provided therein, and a wire terminal assembly
including an electrical terminal that is supported by the terminal
recesses provided in the first and second housing components of the
second electrical connector, wherein portions of the first housing
component and the second housing component engage one another to
retain the first housing component and the second housing component
of the second electrical connector together; wherein the first
electrical connector and the second electrical connector are
identical in structure; and the electrical terminal of the first
electrical connector and the electrical terminal of the second
electrical connector engage one another, and further wherein: (1)
each of the first housing components has a polarizer recess, and
each of the electrical terminals has a polarizer that cooperates
with the polarizing recess; or (2) wherein each of the first
housing components has a polarizer recess provided in the terminal
recess, and each of the electrical terminals has a polarizer that
cooperates with the polarizing recess; or (3) each of the first
housing components has an alignment protrusion, and each of the
electrical terminals has an alignment opening that cooperates with
the alignment protrusion; or (4) wherein each of the first housing
components has a cantilevered arm including both the terminal
recess and a retainer opening, and each of the second housing
components has a retainer that cooperates with the retainer opening
of the first electrical connector to retain the first and second
electrical connectors together; or (5) each of the first housing
components has a cantilevered arm including the terminal recess and
a polarizer recess provided in the terminal recess, and each of the
electrical terminals has a polarizer that cooperates with the
polarizing recess; or (6) the electrical terminal supported within
the first electrical connector includes a first terminal arm and a
second terminal arm; the electrical terminal supported within the
second electrical connector includes a first terminal arm and a
second terminal arm; the first terminal arm of the electrical
terminal supported within the first electrical connector engages
the second terminal arm of the electrical terminal supported within
the second electrical connector; and the second terminal arm of the
electrical terminal supported within the first electrical connector
engages the first terminal arm of the electrical terminal supported
within the second electrical connector; or (7) the electrical
terminal supported within the first electrical connector includes a
first terminal arm, a second terminal arm, and a terminal plug; the
electrical terminal supported within the second electrical
connector includes a first terminal arm, a second terminal arm, and
a terminal plug; the first terminal arm of the electrical terminal
supported within the first electrical connector engages both the
second terminal arm and the terminal plug of the electrical
terminal supported within the second electrical connector; and the
second terminal arm of the electrical terminal supported within the
first electrical connector engages both the first terminal arm and
the terminal plug of the electrical terminal supported within the
second electrical connector; or (8) the electrical terminal
supported within the first electrical connector includes a first
terminal arm and a second terminal arm; the electrical terminal
supported within the second electrical connector includes a first
terminal arm and a second terminal arm; the first terminal arm of
the electrical terminal supported within the first electrical
connector engages the second terminal arm of the electrical
terminal supported within the second electrical connector; and the
second terminal arm of the electrical terminal supported within the
first electrical connector engages the first terminal arm of the
electrical terminal supported within the second electrical
connector; or (9) the electrical terminal supported within the
first electrical connector includes a first terminal arm and a
second terminal arm; the electrical terminal supported within the
second electrical connector includes a first terminal arm and a
second terminal arm; the first terminal arm of the electrical
terminal supported within the first electrical connector engages
the second terminal arm of the electrical terminal supported within
the second electrical connector; and the second terminal arm of the
electrical terminal supported within the first electrical connector
engages the first terminal arm of the electrical terminal supported
within the second electrical connector.
2. The electrical connector assembly defined in claim 1 wherein
each of the first housing components has a locking opening, and
wherein each of the second housing components has a locking arm
that cooperates with the locking opening to connect each of the
first and second housing components together.
3. The electrical connector assembly defined in claim 1 wherein
each of the first housing components has a polarizer recess, and
wherein each of the electrical terminals has a polarizer that
cooperates with the polarizing recess.
4. The electrical connector assembly defined in claim 1 wherein
each of the first housing components has a polarizer recess
provided in the terminal recess, and wherein each of the electrical
terminals has a polarizer that cooperates with the polarizing
recess.
5. The electrical connector assembly defined in claim 1 wherein
each of the first housing components has an alignment protrusion,
and wherein each of the electrical terminals has an alignment
opening that cooperates with the alignment protrusion.
6. The electrical connector assembly defined in claim 1 wherein
each of the first housing components has a cantilevered arm
including both the terminal recess and a retainer opening, and
wherein each of the second housing components has a retainer that
cooperates with the retainer opening of the first electrical
connector to retain the first and second electrical connectors
together.
7. The electrical connector assembly defined in claim 1 wherein
each of the first housing components has a cantilevered arm
including the terminal recess and a polarizer recess provided in
the terminal recess, and wherein each of the electrical terminals
has a polarizer that cooperates with the polarizing recess.
8. The electrical connector assembly defined in claim 1 wherein:
each of the first housing components has a retainer opening; each
of the second housing components has a retainer; the retainer
opening of the first electrical connector cooperates with the
retainer of the second electrical connector to retain the first and
second electrical connectors together; and the retainer opening of
the second electrical connector cooperates with the retainer of the
first electrical connector to retain the first and second
electrical connectors together.
9. The electrical connector assembly defined in claim 1 wherein:
the electrical terminal supported within the first electrical
connector includes a first terminal arm and a second terminal arm;
the electrical terminal supported within the second electrical
connector includes a first terminal arm and a second terminal arm;
the first terminal arm of the electrical terminal supported within
the first electrical connector engages the second terminal arm of
the electrical terminal supported within the second electrical
connector; and the second terminal arm of the electrical terminal
supported within the first electrical connector engages the first
terminal arm of the electrical terminal supported within the second
electrical connector.
10. The electrical connector assembly defined in claim 1 wherein:
the electrical terminal supported within the first electrical
connector includes a first terminal arm, a second terminal arm, and
a terminal plug; the electrical terminal supported within the
second electrical connector includes a first terminal arm, a second
terminal arm, and a terminal plug; the first terminal arm of the
electrical terminal supported within the first electrical connector
engages both the second terminal arm and the terminal plug of the
electrical terminal supported within the second electrical
connector; and the second terminal arm of the electrical terminal
supported within the first electrical connector engages both the
first terminal arm and the terminal plug of the electrical terminal
supported within the second electrical connector.
11. The electrical connector assembly defined in claim 1 wherein:
the electrical terminal supported within the first electrical
connector includes a first terminal arm and a second terminal arm;
the electrical terminal supported within the second electrical
connector includes a first terminal arm and a second terminal arm;
the first terminal arm of the electrical terminal supported within
the first electrical connector engages the second terminal arm of
the electrical terminal supported within the second electrical
connector; and the second terminal arm of the electrical terminal
supported within the first electrical connector engages the first
terminal arm of the electrical terminal supported within the second
electrical connector.
12. The electrical connector assembly defined in claim 1 wherein:
the electrical terminal supported within the first electrical
connector includes a first terminal arm, a second terminal arm, and
a terminal plug; the electrical terminal supported within the
second electrical connector includes a first terminal arm, a second
terminal arm, and a terminal plug; the first terminal arm of the
electrical terminal supported within the first electrical connector
engages both the second terminal arm and the terminal plug of the
electrical terminal supported within the second electrical
connector; and the second terminal arm of the electrical terminal
supported within the first electrical connector engages both the
first terminal arm and the terminal plug of the electrical terminal
supported within the second electrical connector.
Description
BACKGROUND OF THE INVENTION
This invention relates in general to electrical connector
assemblies for selectively providing mechanical and electrical
connections between first and second electrical conductors. In
particular, this invention relates to an improved structure for
such an electrical connector assembly having first and second
electrical connectors that are identical in shape.
In a conventional electrical distribution system, a source of
electrical energy (such as a generator or a battery) supplies
electrical energy through one or more electrical conductors (such
as wires or bus bars) to respective electrically operated devices.
To facilitate the assembly and maintenance of the electrical
distribution system, it is often desirable that some or all of
those electrically operated devices be releasably connected to the
source of electrical energy. This can be accomplished by providing
an electrical connector assembly between respective electrical
conductors extending from the electrically operated devices and the
source of electrical energy. These electrical connector assemblies
are designed to selectively connect and disconnect the respective
electrical conductors (and, therefore, the associated electrically
operated devices and the source of electrical energy) to and from
one another, both mechanically and electrically.
A typical electrical connector assembly includes a first electrical
connector that is connected to a first one of the electrical
conductors and a second electrical connector that is connected to a
second one of the electrical conductors. The first and second
electrical connectors are designed to selectively mate with one
another to provide the mechanical and electrical connections
therebetween. To accomplish this, each of the electrical connectors
usually includes an outer electrically non-conductive housing that
supports an electrically conductive terminal therein. Each of the
terminals is connected to the associated electrical conductor and
is protectively enclosed within the housing to prevent unintended
contact during installation and use. Each of the housings usually
includes one or more retainers that are adapted to cooperate with
corresponding retainers provided on the housing of the mating
electrical connector. When the first and second electrical
connectors are mated with one another to form the electrical
connector assembly, the respective retainers engage one another to
mechanically retain the housings of the electrical connectors
together and electrically engage the terminals of the electrical
connectors with one another.
A wide variety of electrical connector assemblies are known in the
art and have functioned satisfactorily. In most instances, the
first and second electrical connectors have different structures,
such as well known male and female electrical connectors for
example. Although such different electrical connector structures
are effective, they undesirably increase the cost and complexity of
the electrical connector assembly. Thus, it would be desirable to
provide an improved structure for an electrical connector assembly
having first and second electrical connectors that are identical in
shape.
SUMMARY OF THE INVENTION
This invention relates to an improved structure for an electrical
connector assembly having first and second electrical connectors
that are identical in shape. The first electrical connector
includes a first housing component having a terminal recess
provided therein, a second housing component having a terminal
recess provided therein, and a wire terminal assembly including an
electrical terminal that is supported by the terminal recesses
provided in the first and second housing components of the first
electrical connector. The second electrical connector includes a
first housing component having a terminal recess provided therein,
a second housing component having a terminal recess provided
therein, and a wire terminal assembly including an electrical
terminal that is supported by the terminal recesses provided in the
first and second housing components of the second electrical
connector. The electrical terminal of the first electrical
connector and the electrical terminal of the second electrical
connector engage one another.
Various aspects of this invention will become apparent to those
skilled in the art from the following detailed description of the
preferred embodiment, when read in light of the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an electrical connector assembly in
accordance with this invention.
FIG. 2 is a side elevational view of the electrical connector
assembly illustrated in FIG. 1.
FIG. 3 is a sectional elevational view of the electrical connector
assembly illustrated in FIGS. 1 and 2.
FIG. 4 is an exploded perspective view of the electrical connector
assembly illustrated in FIGS. 1, 2, and 3, wherein first and second
identical electrical connectors of the electrical connector
assembly are shown prior to assembly.
FIG. 5 is a side elevational view of the exploded electrical
connector assembly illustrated in FIG. 4.
FIG. 6 is a sectional elevational view of the exploded electrical
connector assembly illustrated in FIGS. 4 and 5.
FIG. 7 is an exploded perspective view from above of one of the
electrical connectors of the electrical connector assembly
illustrated in FIGS. 1 through 6.
FIG. 8 is an exploded perspective view from below of the one of the
electrical connectors of the electrical connector assembly
illustrated in FIG. 7.
FIG. 9 is an enlarged perspective view of one of the terminals of
the electrical connectors illustrated in FIGS. 1 through 8.
FIG. 10 is a sectional elevational view of the terminal illustrated
in FIG. 9.
FIG. 11 is an end elevational view of the terminal illustrated in
FIGS. 9 and 10.
FIG. 12 is an exploded side elevational view of two of the
terminals illustrated in FIGS. 9, 10, and 11 shown prior to
assembly.
FIG. 13 is a sectional elevational view of the two terminals
illustrated in FIG. 12.
FIG. 14 is a side elevational view of the two terminals illustrated
in FIGS. 12 and 13 shown assembled.
FIG. 15 is a sectional elevational view of the two terminals
illustrated in FIG. 14.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, there is illustrated in FIGS. 1
through 8 an electrical connector assembly, indicated generally at
10, in accordance with this invention. The electrical connector
assembly 10 includes a first electrical connector, indicated
generally at 11, and a second electrical connector, indicated
generally at 12. As will be explained in detail below, the first
electrical connector 11 and the second electrical connector 12 are
identical in shape and structure. Thus, only the components of the
first electrical connector 11 will be discussed in detail, and like
reference numbers will be used to indicate the corresponding
identical components of the second electrical connector 12.
The first electrical connector 11 includes a first housing
component 20 that is generally hollow and semi-cylindrical in
shape, extending axially from a first end 21 to a second end 22.
However, the first housing component 20 may have any desired shape.
The first housing component 20 is preferably formed from an
electrically non-conductive material, such as plastic. However, the
first housing component 20 may be formed from any desired material
or combination of materials. A cantilevered arm 23 extends axially
from the second end 22 of the first housing component 20, for a
purpose that will be explained below. A wire recess 24 extends
axially from the first end 21 of the first housing component 20
toward the interior thereof. The illustrated wire recess 24 is
generally semi-cylindrical in shape and includes a plurality (three
in the illustrated embodiment) of semi-annular ribs 24a, although
such is not required. One or more terminal recesses 25 extend
axially from the wire recess 24 to the second end 22 of the first
housing component 20. In the illustrated embodiment, two of such
terminal recesses 25 extend parallel to one another, although such
is not required. A polarizer recess 25a is provided within each of
the terminal recesses 25. The purpose for the polarizer recesses
25a will be explained below.
The first housing component 20 of the first electrical connector 11
also has one or more locking openings 26. In the illustrated
embodiment, six of such locking openings 26 extend completely
through the first housing component 20 (two of which extend through
the cantilevered arm 23). However, a greater or lesser number of
such locking openings 26 may be provided, and some or all of such
locking openings 26 may not extend completely through the first
housing component 20. Additionally, the first housing component 20
of the first electrical connector 11 has one or more alignment
protrusions 27 provided thereon. In the illustrated embodiment, two
of such alignment protrusions 27 are provided on opposite sides of
the first housing component 20. However, a greater or lesser number
of such alignment protrusions 27 may be provided at any desired
locations of the first housing component 20. Also, a retainer
opening 28 is provided in the first housing component 20 for a
purpose that will be described below.
The first electrical connector 11 also includes a second housing
component 30 that is generally hollow and semi-cylindrical in
shape, extending axially from a first end 31 to a second end 32.
However, the second housing component 30 may have any desired
shape. The second housing component 30 is also preferably formed
from an electrically non-conductive material, such as plastic.
However, the second housing component 30 may be formed from any
desired material or combination of materials. A wire recess 33
extends axially from the first end 31 of the second housing
component 30 toward the interior thereof. The illustrated wire
recess 33 is generally semi-cylindrical in shape, although such is
not required. One or more terminal recesses 34 extend axially from
the wire recess 33 to the second end 32 of the second housing
component 30.
The second housing component 30 of the first electrical connector
11 also has one or more locking arms 35. In the illustrated
embodiment, six of such locking arms 35 extend completely inwardly
from the second housing component 30. However, a greater or lesser
number of such locking arms 35 may be provided. As best shown in
FIG. 8, each of the locking arms 35 terminates in an
inwardly-extending lip 35a, although such is not required.
Additionally, the second housing component 30 of the first
electrical connector 11 has one or more alignment openings 36
provided thereon. In the illustrated embodiment, two of such
alignment openings 36 are provided on opposite sides of the second
housing component 30. However, a greater or lesser number of such
alignment openings 36 may be provided at any desired locations of
the second housing component 30. Also, a retainer 37 is provided on
the second housing component 30 for a purpose that will be
explained below.
Lastly, the first electrical connector 11 includes a wire terminal
assembly, indicated generally at 40. The illustrated wire terminal
assembly 40 includes an outer insulator 41 containing one or more
electrical conductors 42. In the illustrated embodiment, two of
such electrical conductors 42 are contained within the outer
insulator 41, although a greater or lesser number may be provided.
Each of the electrical conductors 42 terminates in an electrical
terminal, indicated generally at 43. The illustrated electrical
terminals 43 are identical in shape, although such is not
required.
The structure of one of the electrical terminals 43 is illustrated
in detail in FIGS. 9, 10, and 11. As shown therein, the electrical
terminal 43 includes a wire receiving end 44 that is generally
hollow and cylindrical in shape, although such is not required. A
first terminal arm 45 extends axially from the wire receiving end
44 of the electrical terminal 43. The illustrated first terminal
arm 45 is generally semi-cylindrical in shape, although such is not
required. An optional polarizer 45a extends generally radially
outwardly from the first terminal arm 45. A second terminal arm 46
also extends axially from the wire receiving end 44 of the
electrical terminal 43. The illustrated second terminal arm 46 is
generally semi-cylindrical in shape, although again such is not
required. An optional deformed region 46a is provided at the end of
the second terminal arm 46 for a purpose that will be explained
below.
In the illustrated embodiment, the wire receiving end 44, the first
terminal arm 45, the polarizer 45a, and the second terminal arm 46
are all formed from a single piece of material that is deformed
into the illustrated hollow cylindrical orientation and retained
therein by a plurality of welds 47. However, the wire receiving end
44, the first terminal arm 45, the polarizer 45a, and the second
terminal arm 46 may be formed in any desired manner.
The electrical terminal further includes a terminal plug 48. In the
illustrated embodiment, the terminal plug 48 is solid and
cylindrical in shape. However, the terminal plug 48 may have any
desired shape. As best shown in FIG. 10, the terminal plug 48 is
disposed within the hollow interior of the electrical terminal 43
and is retained therein by one of the welds 47. Thus, the wire
receiving end 44, the first terminal arm 45, the second terminal
arm 46, and the terminal plug 48 of the electrical terminal 43 are
all electrically connected to one another.
The manufacture of the electrical connector assembly 10 of this
invention will now be described with reference to the drawings.
Initially, as best shown in FIG. 7, the wire terminal assembly 40
is initially manufactured by electrically connecting one of the
electrical terminals 43 to the end of each of the electrical
conductors 42 provided within the outer insulator 41. This may be
accomplished in any desired manner, such as by welding, crimping,
and the like.
Next, the wire terminal assembly 40 is aligned with the first
housing component 20 and the second housing component 30, as also
shown in FIG. 7. The wire terminal assembly 40 is then moved into
engagement with the first housing component 20 such that the outer
insulator 41 is received within the wire recess 24 and the
electrical terminals 43 are respectively received within the
terminal recesses 25. When this occurs, the ribs 24a provided in
the wire recess 24, as well as the other portions of the wire
recess 24, engage the outer insulator 41 of the wire terminal
assembly 40. At the same time, the polarizers 45a provided on the
electrical terminals 43 are respectively received within the
polarizer recesses 25a provided in the terminal recesses 25 of the
first housing component 20. Thus, each of the electrical terminals
43 is positively positioned in a precise location relative to the
first housing component 20.
Lastly, the second housing component 30 is moved into engagement
with the first housing component 20 such that the locking arms 35
are received within the locking openings 26 and the alignment
openings 36 receive the alignment protrusions 27. As best shown in
FIGS. 1, 2, 4, 5, and 6, the lips 35a of the locking arms 35 engage
respective portions of the first housing component 20 located about
the peripheries of the locking openings 26. Thus, as best shown in
FIGS. 5 and 6, the first housing component 20 and the second
housing component 30 are retained together to form the assembled
first electrical connector 11, within which the wire terminal
assembly 40 is supported and retained. The second electrical
connector 12 is manufactured in an identical manner.
To complete the manufacture of the electrical connector assembly 10
of this invention, the first electrical connector 11 and the second
electrical connector 12 are initially co-axially aligned with each
other as shown in FIGS. 4, 5, 6, 12, and 13. When so aligned, the
first electrical connector 11 and the second electrical connector
12 are disposed at a 180.degree. opposite orientation relative to
one another. Then, the first electrical connector 11 and the second
electrical connector 12 are moved axially toward one another to the
final assembled position shown in FIGS. 1, 2, 3, 14, and 15.
As a result, an electrically-conductive connection is established
between the wire terminal assembly 40 of the first electrical
connector 11 and the wire terminal assembly 40 of the second
electrical conductor 12. Specifically, as best shown in FIG. 15,
the second terminal arm 46 of the first electrical connector 11 is
received between the first terminal arm 45 and the terminal plug 48
of the second electrical connector 12. Similarly, the second
terminal arm 46 of the second electrical connector 12 is received
between the first terminal arm 45 and the terminal plug 48 of the
first electrical connector 11. Preferably, the deformed regions 46a
of the second terminal arms 46 are flexibly compressed between the
first terminal arms 45 and the terminal plugs 48. This ensures that
a reliable electrical connection is established and maintained
between the first electrical connector 11 and the second electrical
connector 12 and, thus, the respective electrical conductors
42.
Additionally, a mechanical connection is established between the
first electrical connector 11 and the second electrical connector
12. This is accomplished by the retainers 37 provided on the second
housing components 30, which are respectively received within the
retainer openings 28 provided on the first housing components 20,
as best shown in FIG. 3. As a result, a secure mechanical
connection is provided between the first electrical connector 11
and the second electrical connector 12.
The principle and mode of operation of this invention have been
explained and illustrated in its preferred embodiment. However, it
must be understood that this invention may be practiced otherwise
than as specifically explained and illustrated without departing
from its spirit or scope.
* * * * *